2015 CONSTRUCTION ACADEMY BRIDGE CONSTRUCTION

2015 CONSTRUCTION ACADEMY
BRIDGE CONSTRUCTION
FLORIDA DEPARTMENT OF TRANSPORTATION – OFFICE OF CONSTRUCTION
CONTACT INFORMATION
Dan Hurtado, P.E. - State Construction Structures Engineer
Phone: (850) 414-4155
E-mail: [email protected]
John Westphal, P.E. - Construction Structures Engineer
Phone: (850) 414-4141
E-mail: [email protected]
PURPOSE OF SESSION
Heighten awareness of widely misunderstood or
overlooked specifications and other issues
Review specifications that were implemented for
the first time in recent years
Introduce upcoming specification changes that will
significantly impact Contractor and CEI efforts
MAIN TOPICS FOR THIS SESSION
Universal Concerns
Footings
Bearings
Beams
Decks
Concrete Materials
Miscellaneous Topics
Qualifications, Experience, Training
UNIVERSAL CONCERNS
Critical Structures Construction Issues - Self Study Course
Supplement - Critical Structures Construction Issues - Self
Study Course
UNIVERSAL CONCERNS
Administrative Issues
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Bridge Related CPAM Sections
 8.4 – Shop Drawings
 8.11 – Contractor Initiated Submittals
 10.1 – Pile Lengths
 10.2 – PS Concrete Components
 10.3– Concrete Construction
 10.4* – Paint Removal
 10.5 – Drilled Shafts
 10.6 – Underwater Bridge Construction Inspection
 10.7 – Post-tensioned Bridges
 10.8 – Auger Cast Piles
 10.9* – Structural Steel Components
 10.10 – Bridge Construction Issues that Must
Involve State Construction Office Staff
 10.11 – General Structures Construction Issues
*New or Recently Revised Section
UNIVERSAL CONCERNS
Administrative Issues

CPAM 8.4 – Shop and Erection Drawings Process
 9 Item Shop Drawing Tracking Log
 Schedule of shop drawing submittals required from the
Contractor within 60 days of the start of contract
 At weekly progress meetings, ask the Contractor to report
the latest shop drawing priorities, notify reviewers
UNIVERSAL CONCERNS
Administrative Issues

CPAM 8.11 – Contractor Initiated Submittals
 17 items tracking log for each submittal
 There are 3 submittal categories: Request for information (RFI), Request for
Correction (RFC), and Request for Modification (RFM)
 Either tracked in separate logs or category column if single log is used
 Each category has its own processing procedure as covered in CPAM
UNIVERSAL CONCERNS
Administrative Issues

CPAM 10.4 – Paint Removal
 Not only hazardous but potentially hazardous waste
 Makes inspectors aware of coating concerns that are often overlooked,
misunderstood or ignored by Contractors during coating operations
 These concerns are as follows:
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Coating of bolts
Surfaces that are visually difficult to inspect and access
Caulking gaps and seams
Testing for chloride, sulfate and nitrate concentrations
Rigging materials quality
Stripe coating
 Inspectors must pay particular attention to these concerns during coating
operations and they should be discussed in detail with the Contractor at preoperations meetings prior to the start of any work
 CEIs are no longer expected to ensure that the Contractor’s workers are using
the proper safety equipment since OSHA enforcement is not a FDOT
responsibility
UNIVERSAL CONCERNS
Administrative Issues
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CPAM 10.6 – Underwater Bridge Construction Inspection
 Needs to be in Scope of Services for the CEI contract
 Initial inspection is required for concrete voided piles and cylinder piles
 For all other piles, the PA will make the decision about whether or not initial
inspection is needed
 The PA may call for an underwater inspection (progress inspection) at any time
during the construction of the project if there is a question about the condition of an
underwater component
 Inspections must be performed by a qualified commercial diver or an FDOT Certified
Bridge Maintenance Inspection Diver
 Final underwater inspections are required on all projects and must be performed by
a FDOT prequalified Engineering Consulting Firm in the Maintenance Inspection
category or by FDOT District Structures Maintenance Inspectors
UNIVERSAL CONCERNS
Administrative Issues

CPAM 10.9 – Structural Steel and Miscellaneous Metal
Components
 Recently revised and now requires CEIs to keep records of the following tests:
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Job Inspection Snug Tight Torque Test for Bolts
Rotational Capacity Test for Bolts
Steel Girder Shear Connector Bend Test
 Now requires final bolt tension during Snug Tight Torque testing to not exceed
15% above the minimum tension required by the specification topic
 Requests For Correction (RFC) submittals must now be reviewed by the
Inspection Manager of the fabrication plant inspection service retained by the
Department.
 The Inspection Manager will know if a proposed correction to damage or defects
is acceptable or not regarding preapproved fabrication practices or if it sets a
precedent and; thereby, requires higher level consideration by the Department.
 Contractor Must submit a fabrication schedule for all commercial inspection items
e.g. moveable bridge, steel bridge components, mast arms. CEI must forward the
schedule to the SMO. Products must be scheduled enough time in advance to
allow SMO inspection prior to delivery to the jobsite.
UNIVERSAL CONCERNS
Administrative Issues

CPAM 10.10 – Bridge Construction Issues that Must
Involve State Construction Office Staff
Contact us for the following issues:
 Complex superstructure members and complex issues
 Contractor initiated changes to bridge plans, shop drawings,
bridge related specifications or approved means and methods
plans for complex superstructure members and complex issues
 Contractor noncompliance with bridge related contract
documents of complex superstructure members and complex
Issues
 Resolution of bridge member damage or defects for complex
superstructure members and complex issues
UNIVERSAL CONCERNS
Administrative Issues

CPAM 10.11 – General Structures Construction
Issues
 Notifying the District Structures Maintenance Engineer of inservice dates and acceptance inspections
 Notification and monitoring of load rating requirements
 Electronic management of construction documents required
by the District Structures Maintenance Office (DSMO)
 Contractor’s engineer qualification verification
UNIVERSAL CONCERNS
CLASS OF CONTRACTOR’S ENGINEER VERSUS WORK TYPE
Contractor’s
Engineer of
Record
Pre-qualified
Specialty
Engineer
Specialty
Engineer
1) Re-design
Yes
No
No
2) Cost Savings Initiative Proposals
Yes
No
No
3) Details of the permanent work not fully detailed in
the plans (Example: Pot Bearing Design, non-standard
expansion joints, MSE walls, other specialty items)
Yes
Yes
Yes
4) Design and details of the permanent work declared
to be minor or non-structural including minor repairs
Yes
Yes
Yes
Work Type
5) Design and details of the permanent work declared
to be major or structural including major repairs
* The work must also be checked by another pre-qualified
Yes
Yes
*
No
Specialty Engineer
6) Design and drawings of temporary works such as
falsework, formwork, etc.
Yes
Yes
Yes
UNIVERSAL CONCERNS
Administrative Issues

Training and Reference Tools
 Office of Construction and CTQP Websites
contain most structures construction training
materials including piles and drilled shafts as
downloads
 Structures Related Websites:
State Construction Office, Structures Webpage
State Structures Design Office Website
UNIVERSAL CONCERNS
Technical Issues – Concrete Cracks
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Spec. 400-21, Disposition of Cracked
Concrete: the number of cracks is now
taken into account
CPAM Section 10.3.5, Concrete Crack
Inspection: provides instructions for
administering Spec. 400-21
CPAM Section 10.7, Crack and Joint
Inspection of Post-Tensioned Bridges
UNIVERSAL CONCERNS
CPAM Section 10.3.5, Crack Inspection
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Searching for Cracks
 3 cycles: 1) after casting, 2) all dead loads, 3) all live loads
 Early discovery allows crack monitoring and correction of
other components to prevent more cracks
Documenting Observations
 Crack map: length, width, depth, location, cause
 Use pocket microscope for cracks 25 mils or less wide
 Rule of thumb for estimating crack depths on next slide
Disposition of Cracks
 Structural or Non-Structural
 Flow Chart 10-3-5 covers disposition process
UNIVERSAL CONCERNS
CPAM Section 10.3.5, Crack Inspection
UNIVERSAL CONCERNS
Required Contractor Submittals or Actions for
Bridge Temporary Works:
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In recent years the Department has increased the number
and type of temporary works submittals and actions required
of Contractors and this has caused some misunderstandings
and oversights by both Contractors and CEI personnel related
to what is required.
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FOOTINGS
Cofferdam preparation
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Minimal water seepage through sheet piles
Minimal standing water prior to concrete placement
Reserve primary pump capacity plus backup pump
20” or less lift thickness when placing concrete
Planning for cold joints
Mass concrete monitoring
devices protected during
concrete placement
BEARINGS
Specification 400-10.3 Bearing Pads:
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This provision has been revised to ensure that
elastomeric bearing pads are not overextended
or damaged prior to final acceptance
Since the Contractor has no practical way of
avoiding the occasional overextension, the effort
for performing a correction if needed will be
considered as extra work with corresponding
reimbursement
CEI staff shall thoroughly inspect all elastomeric
bearing pads for excess deformation and general
condition prior to final acceptance, and if
possible well before, in order that the Contractor
has ample time to perform corrections before
final acceptance.
BEARINGS
Spec. 460-7.5
Distances between beam bearing centerlines should correspond
very closely to the substructure bearing centerlines and this
should be determined prior to shipping of beams from the
fabrication plant
If there are problems with fit, the Engineer should review any
plan to jack or shift beams once in contact with the bearings and
this may require consultation with the EOR
Anchor bolt holes must not be relocated without approval of the
Engineer and there must expert supervision of any coring
operation
Beam expansion and contraction caused by temperature must be
taken into account when adjusting bearing locations during
erection
BEAMS IN GENERAL
Safety during transport and erection
Review general notes in the plans related to erection
Thorough Inspection when arriving at project site
Falsework structural integrity and stability
Girder Erection Plans and Methods
Erection and stability of long girders is critical (skewed
bearings can be tricky)
This can happen when
bracing methods are
inadequate or when
handling and lifting are
done improperly,
particularly for long
span skewed bridges
BEAMS IN GENERAL
Requirements for construction affecting public safety
Spec. 5-1.4.5.7 and 5-1.5.4
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Contractor must address beam stability with a submittal
Must comply with AASHTO Guide for Temporary works
Must submit an erection plan including signed and sealed
calculations
A Specialty Engineer or his designee must personally inspect
erected structure for compliance with plan prior to traffic
This was recently changed and no longer requires the
designer to do the in-person inspection
Contractor must perform daily inspections of erected
structure and submit inspection records to Engineer
Erection must not take place over active traffic (Spec. 51.4.5.8)
BEAMS IN GENERAL
Revision of Specification 5-1.4.5.6, Beam and Girder Temporary
Bracing
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Where Public Safety is not a concern, the current spec. requires no formal
submittal by the Contractor showing the temporary bracing system for beams
The Contractor must comply with the Table of Temporary Bracing Details.
Where Public Safety is a concern, the current spec. requires signed and
sealed stability calculations to be submitted to the Engineer
As of July 2016 Design Standards, Index 20005 was deleted. Contractors still
must submit signed and sealed drawings showing the temporary bracing
system.
If the Contractor wishes to use a bracing system not covered by Index 20005
than signed and sealed drawings on the system design must be submitted
along with stability calculations (even if proprietary)
BEAMS IN GENERAL
BEAMS IN GENERAL
CONCRETE BEAMS
Spec 450-16
Excessively thick beam buildups are a serious problem
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Adds extra dead load that was not accounted for in the design thus
reducing the strength of the bridge
Wastes concrete: sometimes in very large quantities
Can reduce or eliminate engagement of beam stirrups into deck which
greatly reduces lateral impact resistance and horizontal shear transfer
Solutions to the problem
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Awareness of beam camber values
while beams are in storage at the
prestressed plant
This awareness may allow cap or beam
seat elevations to be raised in time to
avoid excessive buildups
Stirrups can be bent up or inverted hat
shaped rebars can be added
Finished deck grades can be lowered
CONCRETE BEAMS (GL 10B)
Observe the distance between
the top of beam and top of
deck form (slab bottom) at the
start of the forming operation
Most of the stirrup rebars
should extend to or be above
the bottom mat of deck rebars
If most bars do not extend at
least to the bottom of the deck
slab then a correction is
required
Beam cross section showing an
excessively thick beam buildup
The result of lateral impact
to a beam that did not have
stirrups extending through
the interface between deck
slab and beam buildup
If excessive camber occurs?
If camber exceeds by 1 inch the design camber in Plans
Contractor takes appropriate actions (400-7.13.1)
If a D/B Project, the Contractor’s EOR is the designer
CONCRETE BEAMS
Actual camber greater than
estimated camber
Beam must be cast within the
deck which reduces the deck
thickness over the beam
Insertion must not exceed 1”
because,
if
more,
large
aggregate in the concrete will
not fit between the top of the
beam and the bottom mat of
rebars
STEEL BEAMS
Shear stud installation in the field only and bend test
records must be kept (see notes page below for new
specification)
Buy America – all steel, all jobs
No welding of Stay-In-Place form straps on top of girder
flanges
Metal hardware for forms or other
accessories must not be welded to
structural steel unless approved by
the Engineer
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Improper welding can cause imperfections
in the steel that may lead to fatigue
damage or failure
May be permitted if welding is the same as
for shear studs installed in the field
STEEL BEAMS
Bolting (Specification 460)
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Lubrication
Rotational capacity tests
performed in the field
Turn-Of-Nut
Bolt tightening sequence
D T I’s – Direct Tension
Indicators
Bolt Tightening Sequence
The Sequence of Tightening is
CRITICAL
This drawing is included in
the self study course:
FDOT Structures
Inspection PART 2
Skidmore Tension
Analyzer
STRUCTURAL STEEL BOLTING
Checking Snug Tight Tension with a Calibrated Torque Wrench
DIRECT TENSION INDICATIORS BEFORE AND AFTER TIGHTENING
Note: Protrusions are always against the bolt head or nut
BEFORE TIGHTENING
AFTER TIGHTENING
gap
5 mils (0.005 inches)
SQUIRTER DTI’s
STEEL BEAMS
Weathering Steel
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The Department now requires all structural steel
superstructures to be fabricated with weathering
steel which does not require painting and which
will reduce maintenance costs significantly over
the life of the bridge
Some exceptions will be permitted but they must
be approved by the Chief Engineer which will
require rigorous justification by the District
The specification has been revised to address
weathering steel and generally has to do with
protecting concrete surfaces from corrosion
staining
DECKS
Placing sequence and direction
15 mph maximum wind velocity requirement See Spec 400-7.1.3
Evaporation rate monitoring requirements
Excessive fascia beam rotation can
happen because of wide deck
overhangs: Contractor’s must take
this into account when bracing
beams prior to deck placement
Fascia rotation concerns are
especially important for Florida
U-Beams which have no end
diaphragms
DECKS
Florida U-Beam
Deck Overhang
DECKS
Specification 415-5.10.1, Deck Slab Supports, was recently changed
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Slab bolsters used to support the bottom mat of bridge deck rebars can have
continuous rails that are in direct contact with stay-in-place forms regardless of
environmental classification
The only exception is for stay-in-place forms below 12’ above mean high water
elevation in an extremely aggressive environment, in which case, continuous steel
rails are not permitted
Plastic coated steel bolster rails can be in contact with removable forms such as
with deck overhangs, if the environment is slightly aggressive
Continuous plastic high chairs may also be used on removable forms in slightly
aggressive as well as steel continuous high chairs with plastic coated leg tips
Steel bolster rails may not be used on removable forms if the environment is
moderately or extremely aggressive but continuous plastic high chairs or
continuous steel high chairs with plastic tips are allowed
Only continuous plastic high chairs are permitted to be used in an extremely
aggressive environment on removable forms
DECKS
Determining evaporation rate by
measuring weather conditions
 Air temperature
 Relative humidity
 Concrete temperature
 Wind Velocity
Measures are required if rate
exceeds: 0.1 lbs/ft2/hr
Measures to prevent moisture loss
 Application of evaporation
retarder
 Water fogging
 Chilled mix water
 Wind screens
ACI Publication 308R
Evaporation Rate Nomograph
Typical North Florida
Windy Winter Day
Typical Florida
Summer Day
Typical Florida
Summer Night
DECKS
Weather forecasts must be obtained from the
National Weather Service website
http://www.nws.noaa.gov
Input the name of the city closest to the project
site
Under “Additional Forecasts and Information”
select “Hourly Weather Graph” to get the
forecast for the next 48 hours
*Enter city name here
to get the NWS
forecast for the
coming 48 hours
*Select “Hourly Weather
Graph” on the bottom of
the second screen
DECKS
Application of water after screeding (Spec. 400-7.13.3)
With regard to applying curing compound, the following
must be reported to the Engineer (Spec. 400-16):
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How the curing compound spread rate will be determined
The actual curing compound quantity applied during the operation
Compound must be placed under barrier footprint
Placement and maintenance of
curing blankets (over barrier)
DCE Memo 7-11 reminds CEI
staff that Burlap-polyethylene
sheeting used for concrete
curing blankets is required
to have a minimum weight of
9 ounces/square yard
CONCRETE MATERIALS
Mass Concrete (Spec. 346-3.3)
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CPAM Attachment 10.3.4.2 – CEI Verification Process flow chart
First placement requires the mass concrete Specialty Engineer or employee to
personally be on site to check monitoring devices and recording equipment
After first placement a Contractor employee approved by the Specialty Engineer
may verify monitoring devices and equipment
Temperatures recorded every 6 hours until max temperature differential (not
greater than 35 degrees) and max temperature (not greater than 180 degrees) is
reached and begins to diminish
Do not remove the temperature control mechanisms until the core temperature is
within 50°F of the ambient temperature
Specialty Engineer must be available to advise if the differential approaches the 35
degree limit
CEIs must submit all monitoring records as soon as available to the District
Materials Office for review
Core Temperatures much higher
than exterior temperatures
Cool exterior
Temperatures
TYPICAL MASS CONCRETE FOOTING
CONCRETE MATERIALS
CEIs must authorize reduced concrete sampling frequency (from
every 50 cy to every 100cy) with DMO approval before the rate is
implemented
Specification 346-3.1 has recently been revised: requests to use
higher strength concrete for lower strength can be handled
through QC Plans (Contractor/Producer)
Curing boxes at the project site – 60 to 80 degrees (Spec. 346,
Table 5 refers to ASTM C 31)
CONCRETE MATERIALS
When to perform a slump test (Spec 346-7.7)
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Perform a slump test any time there is a question about the water
content of the concrete – consistency must be observed for each truck
Any time water is added at the site, that truck must be tested again
New spec no longer requires a target range
Test all trucks that come after a rejected truck including the first
adjusted truck and begin a new LOT
The location of rejected concrete that is placed, must be documented
so that it can be tested if need be by taking cores
Where to take a slump sample (Spec 346-7.7)
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Samples may be taken out of the back of the truck if buckets are used
and the concrete is discharged from the bucket within 20 minutes
Pump samples must be taken at the end of the hose unless a
correlation that identifies slump change during pumping is approved
by the Engineer
CONCRETE MATERIALS
ACCEPTANCE OF CONCRETE BASED ON
SLUMP TESTING AT THE PROJECT SITE
TOLERANCE SLUMP RANGE ( 3 “ )
REJECT
1-1/2 ” DRY
1-1/2 ” WET
ACCEPT - WATER MUST
NOT BE ADDED
ACCEPT - WATER MUST
NOT BE ADDED
3/4 ” DRY
ACCEPT - NOTIFY
PLANT TO ADJUST &
MAY ADD WATER
AT SITE
REJECT
3/4 ” WET
TARGET
SLUMP
TARGET SLUMP RANGE ( 1-1/2 ” )
ACCEPT - NOTIFY
PLANT TO ADJUST
ACCEPTANCE OF CONCRETE BASED ON
SLUMP TESTING AT THE PROJECT SITE
TOLERANCE SLUMP RANGE ( 3 “ )
REJECT
1-1/2 ” DRY
1-1/2 ” WET
ACCEPT - WATER MAY
BE ADDED
ACCEPT - WATER MAY
BE ADDED
TARGET
SLUMP
VALUE
REJECT
CONCRETE MATERIALS
346-6.3 Delivery Certification: The definition of “Transit Time” on the delivery
ticket has been changed to the time of complete discharge from the concrete truck
So instead of Transit Time being when all concrete in the load is in its final position
in the forms as before, it is now the time when all concrete has been discharged
from the truck
Engineer must approve any placement of concrete in its final position in the forms
that exceeds the Transit Time by greater than 15 minutes as covered in 346-7.2
So, in other words, if the Contractor expects to take more than 15 minutes to
transport the concrete from the back of the truck to the point of final placement,
the Engineer (District Materials Engineer) must approve the time extension
346-7.7 Sample Location: This provision has been changed as follows (new text is
in Italics):
When the concrete is discharged directly from the mixer into the bucket, and
the bucket is discharged within 20 minutes, samples may be obtained from the
discharge of the mixer.
MISCELLANEOUS TOPICS
Specification 400-16.6, Concrete Curing For Traffic Barriers, Railings,
Parapets And End Posts (Specification 400-16.6)
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Apply curing compound within 30 minutes of extrusion as the operation progresses
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Curing compound must remain in place for 7 full days after application (previously
72 hours)
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The following must be reported to the Engineer by the Contractor:
 How the curing compound spread rate will be determined
 The actual curing compound quantity applied during the operation
Applied finish coating (Class V Finish) may be used in lieu of curing compound but
curing compound must be available on site at all times as a backup system to the
Class V material
Specification 521-7, was recently revised and no longer requires cracks in
plain or unreinforced roadway barrier walls to be repaired unless the
Engineer decides that they are too frequent, large or ugly in which case they
will be repaired as determined by the District
MISCELLANEOUS TOPICS
Class 5 Applied Finish Coating (Spec 400-15.2.6.4)
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Spread Rate is 50 ± 10 square feet/gallon
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Contractor must show how the spread rate is computed
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Inspectors must verify that the spread rate is achieved by
observing the operation and measuring process and
recording the results
If the spread rate is in question after application then the
coating thickness can be measured
Consult with the Paul Vinik of the State Materials office for
the correct thickness dimension and measurement
procedure
MISCELLANEOUS TOPICS
Concrete Surface Finish Policy
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A new surface finish policy has recently been implemented which applies CPR
to a previously inconsistent and informal policy
The previous policy was somewhat vague but was widely interpreted for at
least 30 years as requiring almost all bridges to be coated with Class 5 finish
and varied from District to District - Default policy: almost always coat
The new policy is the opposite of the old (see summary table below) and
prohibits Class 5 finish unless specifically approved by a Department Engineer
authorized to do so - Default policy: do not coat unless there is ample
justification
Specification 400-15.1 General Surface Finish, is in the process of being
revised and will require Contractors to use patching mortar that closely
matches the color of the existing concrete instead of non-shrink grout
The patching mortar can be derived from the mix ingredients of the concrete
being patched without large aggregate or it can be blended from a
combination of white cement and gray cement with a trial and error process
to get a close color match
The new policy is expected to bring uniformity to surface finish selection
statewide and to save approximately $1 million a year
MISCELLANEOUS TOPICS
New Standard Indexes 5250, Perimeter Wall
Similar to Noise Walls; precast or masonry
Noise Study and NSR Addendum not required
Walls not designed for vehicle impact
QUALIFICATIONS
Requirements for Technicians Involved with
Concrete Materials, grouting and post-tensioning
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CTQP
CTQP
CTQP
CTQP
CTQP
CTQP
Concrete Field Technician - Level I
Concrete Field Inspector - Level II
Grouting Technician - Level I
Grouting Technician - Level II
Post-Tensioning Technician - Level I
Post-Tensioning Technician - Level II
All these technicians take courses that are offered by agencies that
are not connected with CTQP such as ACI, PTI, and ASBI and that
issue certifications for successful completion
Even though technicians are certified by these agencies they are
not considered qualified for FDOT work until they go through the
extra step of getting qualified by CTQP
If their qualification is not on the CTQP website then they are not
qualified and this applies to CEIs and Contactors
Thank You Everyone!
Contact Info:
John Westphal, P.E.
Construction Structures Engineer
[email protected]